Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
  • B01J37/0027—Powdering
  • B01J37/0045—Drying a slurry, e.g. spray drying
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
  • B01J29/084—Y-type faujasite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/08—Heat treatment
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
  • C10G11/02—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils characterised by the catalyst used
  • C10G11/04—Oxides
  • C10G11/05—Crystalline alumino-silicates, e.g. molecular sieves
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
  • C10G11/14—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts
  • C10G11/18—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "fluidised-bed" technique
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
  • B01J21/005—Spinels
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
  • B01J21/16—Clays or other mineral silicates
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/10—After treatment, characterised by the effect to be obtained
  • B01J2229/20—After treatment, characterised by the effect to be obtained to introduce other elements in the catalyst composition comprising the molecular sieve, but not specially in or on the molecular sieve itself
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/30—After treatment, characterised by the means used
  • B01J2229/42—Addition of matrix or binder particles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/60—Synthesis on support
  • B01J2229/64—Synthesis on support in or on refractory materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
  • B01J29/085—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead
  • B01J29/088—Y-type faujasite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
  • B01J35/63—Pore volume
  • B01J35/633—Pore volume less than 0.5 ml/g
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/107—Atmospheric residues having a boiling point of at least about 538 °C
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/1077—Vacuum residues
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/20—Characteristics of the feedstock or the products
  • C10G2300/201—Impurities
  • C10G2300/205—Metal content
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
  • C10G2400/02—Gasoline

Definitions

• the present invention relates to novel fluid catalytic cracking catalysts comprising microspheres containing Y-faujasite zeolite and having exceptionally high activity and other desirable characteristics, methods for making such catalysts and the use of such catalysts for cracking petroleum feedstocks, particularly under short residence time processes.
• zeolites As an active compone-nt . Such catalysts have taken the form of small particles, called microspheres, containing both an active zeolite component and a non-zeolite component. Frequently, the non-zeolitic component is referred to as the matrix for the zeolitic component of the catalyst.
• the non-zeolitic component is known to perform a number of important functions, relating to both the catalytic and physical properties of the catalyst. Oblad described those functions as follows:
• the matrix is said to act as a sink for sodium in the sieve thus adding stability to the zeolite particles in the matrix catalyst.
• the matrix serves the additional function of: diluting the zeolite; stabilizing it towards heat and steam and mechanical attrition; providing high porosity so that the zeolite can be used to its maximum capacity and regeneration can be made easy; and finally it provides the bulk properties that are important for heat transfer during regeneration and cracking and heat storage in large-scale catalytic cracking.”
• the active zeolitic component is incorporated into the • microspheres of the catalyst by one of two general techniques.
• the zeolitic component is crystallized and then incorporated into microspheres in a separate step.
• the in-situ technique microspheres are first formed and the zeolitic component is then crystallized in the microspheres themselves to provide microspheres containing both zeolitic and non-zeolitic components.
• U.S. Patent No. 4,493,902 discloses novel fluid cracking catalysts comprising attrition-resistant, high zeolitic content, catalytically active microspheres containing more than about 40%, preferably 50-70% by weight Y faujasite and methods for making such catalysts by crystallizing more than about 40% sodium Y zeolite in porous microspheres composed of a mixture of two different forms of chemically reactive calcined kaolin, namely, metakaolin (kaolin calcined to undergo a strong endothermic reaction associated with dehydroxylation) and kaolin calcined under conditions more severe than those used to convert kaolin to metakaolin, i.e., kaolin calcined to undergo the characteristic kaolin exothermic reaction, sometimes referred to as the spinel form of calcined kaolin.
• metakaolin kaolin calcined to undergo a strong endothermic reaction associated with dehydroxylation
• the microspheres containing the two forms of calcined kaolin are immersed in an alkaline sodium silicate solution, which is heated, preferably until the maximum obtainable amount of Y faujasite is crystallized in the microspheres.
• the porous microspheres in which the zeolite is crystallized are preferably prepared by forming an aqueous slurry of powdered raw (hydrated) kaolin (Al0 3 :2Si0 2 : 2H 2 0) and powdered calcined kaolin that has undergone the exotherm together with a minor amount of sodium silicate which acts as fluidizing agent for the slurry that is charged to a spray dryer to form microspheres and then functions to provide physical integrity to the components of the spray dried microspheres .
• powdered raw (hydrated) kaolin Al0 3 :2Si0 2 : 2H 2 0
• sodium silicate acts as fluidizing agent for the slurry that is charged to a spray dryer to form microspheres and then functions to provide physical integrity to the components of the spray dried microspheres .
• the spray dried microspheres containing a mixture of hydrated kaolin and kaolin calcined to undergo the exotherm are then calcined under controlled conditions, less severe than those required to cause kaolin to undergo the exotherm, in order to dehydrate the hydrated kaolin portion of the microspheres and to effect its conversion into metakaolin, this resulting in microspheres containing the desired mixture of metakaolin, kaolin calcined to undergo the exotherm and sodium silicate binder.
• about equal weights of hydrated kaolin and spinel are present in the spray dryer feed and the resulting calcined microspheres contain somewhat more kaolin that has undergone the exotherm than metakaolin.
• the ⁇ 902 patent teaches that the calcined microspheres comprise about 30-60% by weight metakaolin and about 40- 70% by weight kaolin characterized through its characteristic exotherm.
• a less preferred method described in the patent involves spray drying a slurry containing a mixture of kaolin previously calcined to metakaolin condition and kaolin calcined to undergo the exotherm but without including any hydrated kaolin in the slurry, thus providing microspheres containing both metakaolin and kaolin calcined to undergo the exotherm directly, without calcining to convert hydrated kaolin to metakaolin.
• the microspheres composed of kaolin calcined to undergo the exotherm and metakaolin are reacted with a caustic enriched sodium silicate solution in the presence of a crystallization initiator (seeds) to convert silica and alumina in the microspheres into synthetic sodium faujasite (zeolite Y) .
• the microspheres are separated from the sodium silicate mother liquor, ion-exchanged with rare earth, ammonium ions or both to form rare earth or various known stabilized forms of catalysts.
• the technology of the 902 patent provides means for achieving a desirable and unique combination of high zeolite content associated with high activity, good selectivity and thermal stability, as well as attrition-resistance.
• the aforementioned technology has met widespread commercial success .
• custom designed catalysts are now available to oil refineries with specific performance goals, such as improved- activity and/or selectivity without incurring costly mechanical redesigns.
• a significant portion of the FCC catalysts presently supplied to domestic and foreign oil refiners is based on this technology.
• a cracking catalyst can have outstandingly high cracking activity, but if the activity results in a high level of conversion to coke and/or gas at the expense of gasoline the catalyst will have limited utility.
• Catalytic cracking activity in present day FCC catalysts is attributable to both the zeolite and non- zeolite (e.g., matrix) components. Zeolite cracking tends to be gasoline selective. Matrix cracking tends to be less gasoline selective. After appropriate ion-exchange treatments with rare earth cations, high zeolite content microspheres produced by the in situ procedure described in the ⁇ 902 patent are both highly active and highly gasoline selective.
• the activity and selectivity characteristics of the catalysts formed by the process of the ⁇ 902 patent are achieved even though, in general, the catalysts have relatively low total porosity as compared to fluid catalytic cracking catalysts prepared by incorporating the zeolite content into a separate matrix.
• the microspheres of such catalysts in some cases, have a total porosity of less than about 0.15 cc/g. or even less than about 0.10 cc/g.
• the microspheres of the ⁇ 902 patent have a total porosity of less than 0.30 cc/g.
• total porosity means the volume of pores having diameters in the range of 35-20, 000A , as determined by the mercury porosimetry technique.
• microspheres having a total porosity of less than about 0.15 cc/g. exhibit the activity and selectivity characteristics found. For example, such a result is contrary to the prior art disclosures that low pore volumes "can lead to selectivity losses due to diffusional restrictions.”
• the attrition resistance of the microspheres prepared in accordance with the ⁇ 902 patent was superior to the conventional FCC catalysts in which the crystallized zeolite catalytic component was physically incorporated into the non- zeolitic matrix.
• FCC apparatus have been developed which drastically reduce the contact time between the catalyst and the feed which is to be cracked.
• the reactor is a riser in which the catalyst and hydrocarbon feed enter at the bottom of the riser and are transported through the riser. The hot catalyst effects cracking of the hydrocarbon during the passage through the riser and upon discharge from the riser, the cracked products are separated from the catalyst.
• the catalyst is then delivered to a regenerator where the coke is removed, thereby cleaning the catalyst and at the same time providing the necessary heat for the catalyst in the riser reactor.
• the newer riser reactors operate at lower residence time and higher operating temperatures to minimize coke selectivity and delta coke.
• Several of the designs do not even employ a riser, further reducing contact time to below one second. Gasoline and dry gas selectivity can improve as a result of the hardware changes.
• the highly porous precursor microspheres are formed by spray drying a slurry of hydrous kaolin, which is characterized by the presence of a major amount of large (greater than 2 microns) kaolin stacks along with spinel calcined kaolin.
• hydrous kaolin When spray dried, the coarse hydrous kaolin results in microspheres having a desired high content of macropores in which the zeolite Y can grow.
• U.S. Patent No. 5,023,220 to Dight, et. al . also increases the macroporosity of the precursor microspheres by spray drying a mixture of hydrous kaolin, metakaolin and spinel.
• These catalyst microspheres have a substantial level of zeolite and are very active and selective.
• the high alumina, silica-alumina matrix portion of the catalysts is often totally surrounded by the zeolite formed in-situ such that the matrix is only now understood to provide a reduced level of bottoms cracking under the short contact time FCC conditions .
• novel zeolite microspheres are disclosed. These zeolite microspheres are macroporous, have sufficient levels of zeolite to be very active and are of a unique morphology to achieve effective conversion of hydrocarbons to cracked gasoline products with improved bottoms cracking under SCT FCC processing.
• the novel zeolite microspheres are produced by novel processing, which is a modification of technology described in U.S. Patent No. 4,493,902. It has been found that if the non-zeolite, alumina-rich matrix of the catalyst is derived from an ultrafine hydrous kaolin source having a particulate size such that 90 wt.
• the FCC catalyst matrix useful to achieve FCC catalyst macroporosity is derived from alumina sources, such as kaolin calcined through the exotherm, that have a specified water pore volume, which distinguishes over prior art calcined kaolin used to form the catalyst matrix.
• the water pore volume is derived from an Incipient Slurry Point (ISP) test, which is described in the application.
• the morphology of the microsphere catalysts which are formed is unique relative to the in-situ microsphere catalysts formed previously.
• Use of a pulverized, ultrafine hydrous kaolin calcined through the exotherm yields in-situ zeolite microspheres having a macroporous structure in which the macropores of the structure are essentially coated or lined with zeolite subsequent to crystallization.
• Macroporosity as defined herein means the catalyst has a macropore volume in the pore range of 600 - 20,000 A of at least 0.07 cc/gm mercury intrusion.
• the novel catalyst is optimal for FCC processing, including the short contact time processing in which the hydrocarbon feed is contacted with a catalyst for times of about 3 seconds or less. In the broadest sense, the invention as disclosed in
• U.S. Serial No. 09/956,250 is not restricted to macroporous catalysts having a non-zeolite matrix derived solely from kaolin.
• any alumina source which has the proper combinations of porosity and reactivity during zeolite synthesis and can generate the desired catalyst macroporosity and morphology can be used.
• the desired morphology comprises a matrix which is well dispersed throughout the catalyst, and the macropore walls of matrix are lined with zeolite and are substantially free of binder coatings . Accordingly, not only is the large pore surface area of the catalyst vastly improved over previous catalysts, and the active matrix dispersed throughout the microsphere, the zeolite crystals are readily accessible to the hydrocarbon feed.
• a novel macroporous in-situ-formed zeolite catalyst is provided by forming a precursor reactive microsphere which contains reactive metakaolin and inert hydrous kaolin.
• the microsphere is reacted with an alkaline silicate solution to form the zeolite crystals.
• the presence of the hydrous kaolin as a matrix precursor has been found to yield a macroporous structure on the order of that disclosed in the aforementioned copending application, U.S. Serial No. 09/956,250.
• the macroporous structure is achieved using a calcined, ultra-fine hydrous kaolin as the matrix precursor.
• the catalyst of this invention can also include a matrix derived in part from kaolin calcined through the characteristic exotherm, as well as a calcined boehmite alumina which has been found useful for metal passivation.
• metakaolin, hydrous kaolin, and a silicate binder are spray dried to form a precursor reactive microsphere.
• the hydrous kaolin is maintained as an inert component even if the as-spray dried microsphere is calcined by calcining at a lower temperature and avoiding the endothermic transformation of hydrous kaolin to metakaolin.
• the inert hydrous kaolin is not consumed under the caustic crystallization conditions .
• the metakaolin provides the reactive silica and alumina for crystallization and also enables the presence of high pore volume in the spray dried microsphere.
• the amount of metakaolin, or more generally, the amount of soluble alumina available to crystallize zeolite, is limited so that yield of zeolite is limited during the crystallization resulting in a sufficient macroporosity.
• Catalysts of the invention are made by spray drying a feed mixture of hydrated kaolin, metakaolin, and a binder such as silica sol or sodium silicate.
• the spray dried microspheres are optionally acid-neutralized and washed to reduce sodium content.
• the spray dried microsphere are preferably subsequently calcined to form precursor porous microspheres .
• the hydrous kaolin is maintained as an inert component by calcining at lower temperatures so as to avoid the endothermic transformation of the hydrous kaolin component to metakaolin. Calcination temperatures of less than 1000°F, preferably less than 800°F, can be used to calcine the spray dried microspheres .
• the amount of metakaolin in the spray dried and optionally calcined microspheres provides the soluble alumina available to grow zeolite,.
• the amount of metakaolin present in the spray dried microspheres is limited with respect to the inerts such as hydrous kaolin so that the yield of zeolite is limited during crystallization.
• An excessive level of metakaolin in the reactive microsphere would yield a high level of zeolite that would reduce the porosity of the microsphere to an undesired low level.
• the spray dried microspheres after optional calcination will contain a metakaolin content of up to 50 wt.%, preferably up to 45 wt%, and more preferably will be present in amounts of 30- 40 wt%.
• Any binder used should contain only sodium, expressed as Na 2 0, which is easily removed.
• silica or silicate binders traditionally used do bring these nutrients into the zeolite crystallization process, their main purpose is to provide mechanical strength to the green microspheres sufficient to withstand processing up until crystallization. Therefore, any binder capable of fulfilling this role while not interfering with the other constraints laid out herein would be adequate.
• Aluminum chlorohydrol for example might be useful.
• the precursor microspheres are reacted with zeolite seeds and an alkaline sodium silicate solution, substantially as described in U.S. Patent No. 5,395,809, the teachings of which are incorporated herein by cross- reference.
• the microspheres are crystallized to a desired zeolite content (typically ca. 40-75%), filtered, washed, ammonium exchanged, exchanged with rare-earth cations if required, calcined, exchanged a second time with ammonium ions, and calcined a second time if required.
• compositions of the solids in the slurries that are spray dried to form porous microspheres, and later optionally calcined at low temperature to prepare precursor reactive microspheres are expressed hereinafter below in Table 1 as the weight percent of metakaolin and inerts including hydrated kaolin, calcined boehmite for metal passivation, and kaolin calcined through the exotherm (spinel or mullite) on a binder-free basis; weight % Si0 2 binder is based on the grams of Si02 in the binder per gram of total weight of moisture-free spray dried microspheres and provided by sodium silicate.
• the spray dried microspheres will have a size of from about 20 to 150 microns.
• the size of the spray dried microspheres will range from about 50 to 100 microns and, more preferably, from about 65-90 microns.
• Hydrous kaolin is used as an inert in the slurry and acts as an alumina-containing matrix precursor of the catalyst.
• the zeolite catalyst will contain a silica-alumina matrix derived from the hydrous kaolin.
• the hydrous kaolin used as the alumina- containing matrix precursor of the catalytic microspheres is not singularly critical and can be obtained from a wide variety of commercial sources.
• the hydrous kaolin can suitably be either one or a mixture of ASP ® 600 or ASP ® 400 kaolin, derived from coarse white kaolin crudes. Finer particle size hydrous kaolins can also be used, including those derived from gray clay deposits, such as LHT pigment.
• Purified water-processed kaolins from Middle Georgia have been used with success.
• the particle size of the hydrous kaolin is generally known to have an impact on microsphere porosity, so the resultant crystallized catalyst macroporosity can be manipulated in part by manipulation of the hydrous kaolin particle size.
• the present assignee for example has shown that coarser hydrous kaolin yields higher macropore volume in microspheres. Since the present invention comprises several parameters that effect changes in catalyst macroporosity, there remains some flexibility in the choice of the hydrous kaolin particle size.
• Silicate for the binder is preferably provided by sodium silicates with Si0 2 to Na 2 0 ratios of from 1.5 to 3.5 and especially preferred ratios of from 2.00 to 3.22.
• the non-zeolitic, alumina-containing matrix of the catalysts of the present invention can further be derived in part from a hydrous kaolin source that is in the form of an ultrafine powder that is pulverized and calcined through the exotherm.
• Typical zeolite microspheres have been formed with an alumina-containing matrix derived from kaolin having a larger size than used in this invention and which is calcined at least substantially through its characteristic exotherm.
• Satintone® No. 1 (a commercially available kaolin that has been calcined through its characteristic exotherm without any substantial formation of mullite) is a material used on a commercial basis to form the alumina-containing matrix.
• Satintone® No. 1 is derived from a hydrous kaolin in which 70% of the particles are less than 2 microns.
• Other sources having been used to form the alumina-containing matrix include finely divided hydrous kaolin (e.g., ASP® 600, a commercially available hydrous kaolin described in Engelhard Technical Bulletin No. TI-1004, entitled “Aluminum Silicate Pigments” (EC-1167)) calcined at least substantially through its characteristic exotherm.
• Booklet kaolin has found the most widespread commercial use and has met tremendous success worldwide.
• these larger kaolin particles represented the state of the art in forming the alumina-containing matrix of the catalyst microsphere and had no perceived deficits. What is meant by "ultrafine" powder is that at least
• hydrous kaolin particles must be less than 2 microns in diameter, preferably less than 1 micron determined by SedigraphTM (or sedimentation) . It has been found that, in particular, use of hydrous kaolin pigments with this particle size distribution upon pulverization and calcination through the characteristic exotherm results in a greater quantity of macroporosity in the catalyst microsphere subsequent to zeolite crystallization.
• the loose packing of the calcined ultrafine kaolin which has been found, can be likened to a "house of cards" in which the individual particulates are aligned randomly with respect to adjacent particles in a non-parallel manner.
• the calcined ultrafine kaolin exists as porous aggregates of the "house of cards" morphology, providing not only a porous aggregate but additional porous areas between aggregates.
• Pulverization of the ultrafine hydrous kaolin is required to provide the random stacking of the individual kaolin platelets.
• the pulverized ultrafine hydrous kaolin optionally used to derive a portion of the alumina-containing matrix, is calcined through its characteristic exotherm with or without the formation of mullite.
• An especially preferred matrix source which can be used in this invention to form in part the macroporous zeolite microspheres is Ansilex® 93.
• Ansilex® 93 is made from the fine size fraction of a hard kaolin crude, by spray drying, pulverizing and calcining to prepare low abrasion pigments as described in U.S. Patent No. 3,586,523, to Fanselow, et. al . , the entire contents of which are herein incorporated by reference.
• the ultrafine hydrous matrix source is spray dried, pulverized and then calcined through the exotherm, optionally to mullite.
• the aforementioned U.S. Patent No. 4,493,902 discloses calcining the kaolin to mullite until the X-ray diffraction intensities are comparable to a fully crystalline reference standard.
• the ultrafine hydrous kaolin beyond the exotherm such that the X-ray diffraction intensities are comparable to a fully crystalline referenced standard as disclosed in the ⁇ 902 patent
• the small crystallite size mullite has the appropriate diffraction lines and leached chemical composition of a fully crystalline mullite standard, but the diffractional lines are weaker inasmuch as the crystallites are smaller.
• the relationship between diffraction intensity/line width and crystallite size is well-known.
• the ultrafine hydrous kaolin calcined through the exotherm has 20-80% of the integrated X-ray diffraction peak areas of a kaolin reference sample containing well crystallized mullite.
• the ultrafine kaolin is calcined through the exotherm such that it has 50-70% of the integrated X-ray diffraction peak areas of fully crystallized mullite.
• Ansilex® material is that it is derived from hard kaolin.
• Hard kaolins typically have a gray tinge or coloration and are, thus, also referred to as "gray clays". These hard kaolins are further characterized by breaking into irregularly shaped fragments having rough surfaces .
• Hard kaolins also contain a significant iron content, typically about 0.6 to 1 wt. % of Fe 2 0 3 .
• Hard kaolin clays are described in Grim' s "Applied Clay Mineralogy", 1962, MaGraw Hill Book Company, pp. 394-398 thereof, the disclosure of which is incorporated by reference herein. The use of these materials to form part of the alumina- containing matrix for in situ FCC microsphere catalysts has not been known previous to U.S. Serial No. 09/956,250 although their use in the incorporated routes is well established. Hard kaolins have also occasionally been used as sources of metakaolin for in situ microspheres, but not with advantage .
• the matrix can be derived at least in part from alumina-containing materials more generally characterized by the porosity thereof provided during the packing of the calcined material.
• a test has been developed to determine the pore volume of the calcined alumina-containing material which can be used to ultimately form a part of the matrix of the inventive catalyst. The test characterizes the water pore volume of the calcined alumina-containing material by determining the minimum amount of water needed to make a slurry from a sample of the solids. In the test, a powder sample is mixed with water containing a dispersant such as, for example,
• ISP incipient slurry point
• incipient slurry point percent solids values indicate higher water absorption capacities or higher pore volume in the sample.
• the calcined alumina-containing materials from which the high- alumina matrix can be at least in part derived in accordance with this invention will have incipient slurry points less than 57% solids, preferably 48 to 52% solids. This compares with Satintone® No. 1 which yields over 58% solids in the incipient slurry point test.
• the ultrafine hydrous kaolin useful as an alumina-containing material which can be used to derive a portion of the matrix of the catalyst microspheres, but the matrix may also be derived in part from delaminated kaolin, platelet alumina and precipitated alumina.
• Means for delaminating booklets or stacks of kaolin are well-known in the art. Preferred are those methods, which use a particulate grinding medium such as sand, or glass microballoons as is well-known.
• the platelets are pulverized to derive the random packing or "house of cards" morphology.
• An advantage of the matrix precursors meeting the ISP test specification is that they bring higher pore volume per unit matrix surface area. This maximizes the effectiveness of the catalyst by minimizing both catalytic coke (pore volume) and contaminant coke (matrix surface area) .
• the rapid hydrolysis method involves adding ammonium hydroxide solution to the mixture and drying in air.
• Xerogels prepared by the slow hydrolysis method crystallized mullite directly from the amorphous state on firing whereas the xerogels formed by rapid hydrolysis crystallized a spinel phase before mullite formation.
• such materials can be used to derive at least in part the high- alumina matrix of the catalyst of this invention.
• the catalyst matrix may further include an alumina source derived from highly dispersible boehmite.
• aluminas such as pseudo-boehmite with low dispersibility, and gibbsite can be used, but are not as effective.
• Dispersibility of the hydrated alumina is the property of the alumina to disperse effectively in an acidic media such as formic acid of pH less than about 3.5. Such acid treatment is known as peptizing the alumina. High dispersion is when 90% or more of the alumina disperses into particles less than about 1 micron.
• the surface area (BET, nitrogen) of the crystalline boehmite, as well as the gamma - delta alumina conversion product, upon calcination is below 150 m 2 /g, preferably below 125 m 2 /g, and most preferably below 100 m 2 /g, e.g. 30 - 80 m 2 /g.
• the crystalline boehmite is calcined prior to incorporation into the microsphere.
• the crystalline boehmite is converted to a porous gamma phase and to a lesser extent a delta alumina.
• the BET surface area of this material only increases marginally, e.g., increases from 80 m 2 /g to 100 m 2 /g.
• the calcined boehmite converted to the gamma phase is added to the slurry of hydrous kaolin, metakaolin, and other alumina matrix components and spray dried into the microspheres .
• the gamma alumina Upon zeolite crystallization, the gamma alumina will not be leached from the microspheres by the alkaline silicate solution.
• the dispersed alumina solution is calcined and spray dried with the kaolin and binder, the resulting microsphere contains uniformly distributed gamma alumina throughout the microsphere .
• the pore volume of the crystallized zeolite microsphere of this invention which is formed using hydrous kaolin to form the catalyst matrix, is greater than 0.15 cc/gm, more preferably greater than 0.25 cc/gm, and most preferably greater than 0.30 cc/gm of Hg in the range of 40-20, 000A diameter.
• the catalyst of this invention has a macropore volume within pores having a size range of 600 to 20,000A of at least 0.07 cc/gm of Hg, and preferably at least 0.10 cc/gm of Hg. While conventional zeolite-incorporated catalysts have macroporosities comparable to the catalysts of this invention, the incorporated catalysts do not have the novel zeolite-on-matrix morphology nor performance of the catalysts of this invention.
• the catalysts of this invention will have a BET surface area less than 500 m/g, preferably less than 475 m 2 /g and most preferably within a range of about 300-450 m 2 /g.
• the moderate surface area of the catalysts of this invention in combination with the macroporosity achieves the desired activity and selectivities to gasoline while reducing gas and coke yields .
• One skilled in the art will readily appreciate that it is the steam-aged surface area and activity that is truly significant and which must be balanced against the available pore volume.
• the cited preferred surface areas for finished product (fresh) catalyst are chosen such that the surface area after a 1500° F, four hour steaming at 1 atm steam pressure are generally below 300 m2/gm.
• the macroporosity of the catalyst of this invention is maintained even if a portion of the matrix is derived from calcined or additional coarse alumina-containing materials which otherwise have a low water pore volume as determined by the ISP test described above.
• a quantity (e.g., 3 to 30% by weight of the kaolin) of zeolite initiator may also be added to the aqueous slurry before it is spray dried.
• the term zeolite initiator may also be added to the aqueous slurry before it is spray dried.
• zeolite initiator shall include any material containing silica and alumina that either allows a zeolite crystallization process that would not occur in the absence of the initiator or shortens significantly the zeolite crystallization process that would occur in the absence of the initiator. Such materials are also known as “zeolite seeds”.
• the zeolite initiator may or may not exhibit detectable crystallinity by x-ray diffraction. Adding zeolite initiator to the aqueous slurry of kaolin before it is spray dried into microspheres is referred to herein as "internal seeding". Alternatively, zeolite initiator may be mixed with the kaolin microspheres after they are formed and before the commencement of the crystallization process, a technique which is referred to herein as "external seeding".
• the zeolite initiator used in the present invention may be provided from a number of sources.
• the zeolite initiator may comprise recycled fines produced during the crystallization process itself.
• Other zeolite initiators that may be used include fines produced during the crystallization process of another zeolite product or an amorphous zeolite initiator in a sodium silicate solution.
• amorphous zeolite initiator shall mean a zeolite initiator that exhibits no detectable crystallinity by x-ray diffraction.
• the seeds may be prepared as disclosed by in 4,493,902. Especially preferred seeds are disclosed in 4,631,262.
• the microspheres may be calcined at low temperature, e.g., for two to four hours in a muffle furnace at a chamber temperature of less than 1000° F. It is important that during calcination the hydrated kaolin component of the microspheres is not converted to metakaolin, leaving the hydrous kaolin, and optional spinel or gamma alumina components of the microspheres essentially unchanged.
• the microspheres may be acid-neutralized to enhance ion exchange of the catalysts after crystallization.
• the acid-neutralization process comprises co-feeding uncalcined, spray dried microspheres and mineral acid to a stirred slurry at controlled pH.
• the rates of addition of solids and acid are adjusted to maintain a pH of about 2 to 7, most preferably from about 2.5 to 4.5 with a target of about 3 pH.
• the sodium silicate binder is gelled to silica and a soluble sodium salt, which is subsequently filtered and washed free from the microspheres.
• the silica gel-bound microspheres are then calcined at low tempature.
• Y-faujasite is allowed to crystallize by mixing the kaolin microspheres with the appropriate amounts of other constituents (including at least sodium silicate and water) , as discussed in detail below, and then heating the resulting slurry to a temperature and for a time (e.g., to 200°-215° F. for 10-24 hours) sufficient to crystallize Y- faujasite in the microspheres.
• the prescriptions of 4,493,902 may be followed as written. Equivalent, reformatted recipes are provided as follows, however.
• the crystallization recipes we employ are based on a set of assumptions and certain raw materials.
• the seeds are described by 4,631,262 and are preferably used externally.
• the Si02, A1203, and Na20 components of metakaolin, seeds, sodium silicate solution, calcined sodium silicate binder, and silica gel are assumed to be 100% reactive.
• the silica-alumina and alumina derived from the hydrous kaolin and calcined boehmite, respectively, are assumed to be completely unreactive for zeolite synthesis.
• the alumina and silica in kaolin calcined through the exotherm to the spinel form are assumed to be 1% and 90% reactive respectively. Although these two values are in use, they are not believed to be accurate.
• the alumina and silica in kaolin calcined through the exotherm to the mullite form are assumed to be
• the sodium silicate and sodium hydroxide reactants may be added to the crystallization reactor from a variety of sources.
• the reactants may be provided as an aqueous mixture of N® Brand sodium silicate and sodium hydroxide.
• at least part of the sodium silicate may be provided by the mother liquor produced during the crystallization of another zeolite- containing product.
• the microspheres containing Y-faujasite are separated from at least a substantial portion of their mother liquor, e.g., by filtration. It may be desirable to wash to microspheres by contacting them with water either during or after the filtration step. The purpose of the washing step is to remove mother liquor that would otherwise be left entrained within the microspheres .
• “Silica Retention” may be practiced.
• the teachings of U.S. Patent No. 4,493,902 at column 12, lines 3-31, regarding silica retention are incorporated herein by cross-reference .
• the microspheres After crystallization by reaction in a seeded sodium silicate solution, the microspheres contain crystalline Y- faujasite in the sodium form.
• the ion exchange step or steps are preferably carried out so that the resulting catalyst contains less than about 0.7%, most preferably less than about 0.5% and most preferably less than about 0.4%, by weight Na 2 0.
• the microspheres are dried to obtain the microspheres of the present invention.
• the Na + cations are exchanged by using only an ammonium salt such as NHN0 3 and without using any rare earth salt during exchange.
• Such 0 (zero) wt . % REO catalysts are especially beneficial as FCC catalysts that give higher octane gasoline and more olefinic product.
• Rare earth versions of catalysts of this invention post treated after crystallization by ion- exchange with high levels of rare earth, e.g., by procedures such as described in the ⁇ 902 patent, are useful when exceptionally high activity is sought and the octane rating of the FCC gasoline produce is not of prime importance. Rare earth levels in the range of 0.1% to 12% usually between 0.5% and 7% (weight basis) are contemplated. Following ammonium and rare earth exchange, the catalyst is calcined at 1100°-1200° F. for 1 - 2 hours and unit cell size of the Y zeolite is reduced.
• this calcination is done in a covered tray with 25% free moisture present.
• the preferred catalyst of the invention comprises microspheres containing at least 15% and preferably from 40 to 65% by weight Y faujasite, expressed on the basis of the as-crystallized sodium faujasite form zeolite.
• Y faujasite shall include synthetic faujasite zeolites exhibiting, in the sodium form, an X- ray diffraction pattern of the type described in Breck, Zeolite Molecular Sieves, p.
• Y faujasite shall encompass the zeolite in its sodium form as well as in the known modified forms, including, e.g., rare earth and ammonium exchanged forms and stabilized forms.
• the percentage of Y faujasite zeolite in the microspheres of the catalyst is determined when the zeolite is in the sodium form (after it has been washed to remove any crystallization mother liquor contained within the microspheres) by the technique described in the ASTM standard method of testing titled "Relative Zeolite Diffraction Intensities" (Designation D3906-80) or by an equivalent technique. It is important to equilibrate the microspheres carefully before X-ray evaluations are made since equilibration can have a significant effect on the results .
• the Y-faujasite component of the microspheres in their sodium form, have a crystalline unit cell size of less than about 24.73 A and most preferably less than about 24.69 A.
• Table 2 below sets forth ranges for the chemical composition and surface areas of catalysts formed in accordance with this invention.
• catalysts of this invention that contain the calcined dispersable boehmite are particularly useful in cracking residuum and resid-containing feeds having a Ni+V metals content of at least 2,000 ppm and a Conradson carbon content greater than 1.0.
• the catalyst of the present invention like all commercial fluid catalytic cracking catalysts, will be hydrothermally deactivated during the operation of the cracking unit. Accordingly, as used herein, the phrase "cracking the petroleum feedstock in the presence of a catalyst” shall include cracking the petroleum feedstock in the presence of the catalyst in its fresh, partially deactivated, or fully deactivated form.
• the catalyst microspheres of this invention have a substantially different morphology than the previous catalyst microspheres, especially with respect to the increased pore volume, zeolite-on-matrix morphology, and moderate surface area. Attrition resistance of these catalysts is good and effective for the SCT FCC processing conditions .
• the method of preparation and subsequent properties such as mercury pore volume, the catalyst of this invention includes a macroporous matrix in which the macropores of the matrix are formed from a random configuration of porous matrix planar structures which are lined with the zeolite crystals.
• the macropores of the catalyst are lined with the active zeolite crystals.
• the macroporosity of the catalyst allows the hydrocarbons to enter the catalyst freely and the increased macropore surface area thereof allows such hydrocarbons to contact the catalytic surfaces .
• the hydrocarbons can contact the zeolite unobstructed, rendering the catalyst very active and selective to gasoline.
• conventional incorporated zeolite catalysts in which the zeolite crystals are incorporated within a binder and/or matrix, have a highly porous matrix, at least a portion of the binder coats or otherwise obstructs the zeolite crystals.
• microspheroidal catalysts there is no need for a separate physical binder which glues the zeolite to the matrix surface other than any minute amounts of silicate which may remain subsequent to zeolite crystallization. It is believed that the microsphere catalysts formed in accordance with the process of the present invention yield the highest accessibility to the zeolite of any zeolite/matrix catalyst. Also optionally present in a highly dispersed state are the particles of metal-passivating alumina. While there is a preponderance of zeolite lining the macropore walls of the invention, smaller particles presumed to be formed from the dispersed boehmite and/or mullite are also seen.
• microspheroidal catalysts of the present invention provide high conversions via low coke_selectivity and higher selectivities to gasoline relative to previous FCC catalysts presently on the market. It is surprising that this catalyst can consistently outperform conventional incorporated catalysts of similar or even higher porosity and lower surface area. This shows that having added porosity alone is not sufficient. It is now believed that the novel structured catalysts, being both macroporous and with the macropore walls lined with zeolite and with the mesoporous or microporous matrix substantially behind the zeolite layer are the reasons the catalyst excels at gasoline, LCO and coke selectivity. The present catalyst is sufficient to crack the heavier hydrocarbons and anticipated to improve the API gravity of the bottom fraction, especially during the short contact time processing.
• EXAMPLE 1 The microspheres of this Example were made in a pilot plant with nozzle-type atomizer. The following components as set forth in Table 3 were mixed in a Cowles mixer and spray dried. The sodium silicate was added directly to the slurry, resulting in flocculation. Solids were adjusted appropriately in order to enable spray drying.
• microspheres were calcined at 700°F for 4 hours before further use.
• the as- crystallized sample of Example 2 had a Hg pore volume of 0.31 cc/g (40-20K pore diameter).
• EXAMPLES 4 and 5 The microspheres of Examples 4 and 5 contain 5 ultrafine kaolin (Ansilex 93 ® ) calcined through the characteristic exotherm and were spray dried at a Pilot plant with a wheel-type atomizer. The weight percentages of each component forming the spray dried slurry are shown in Table 5. The weight percentage of each kaolin component is on a binder-free basis.
• Silicate binder (as Si0 2 ) 15 15 1. Engelhard Corporation, USA. 70% ⁇ 2um by sedimentation hydrous kaolin.
• the spray dried microspheres were calcined at 700°F for 4 hours before further use.
• Microsphere Example 4 Example 5 grams microsphere 750 750 grams seeds 516 516 grams N-Brand 1361 1215 grams 50% caustic 166 187 grams water 726 772
• Example 6 390 77 0.49 3.03 60.51 33.44 24 .526 11 0.40
• Ansilex-93 ® gives rise to an increased pore volume in the range of 25-30 A pore radius. All of the above catalyst examples did not contain metal tolerant alumina and are intended for cracking of a feed with a minimum metals content.
• EXAMPLES 8 and 9 These examples disclose the preparation of microsphere containing metal tolerant alumina.
• metal tolerant highly dispersable boehmite was first calcined at 1450°F for 2h to gamma alumina. The gamma alumina was then milled to reduce APS to about 2 microns in aqueous media. The milled gamma alumina slurry, either peptized or not, was added to a slurry containing metakaolin, hydrous kaolin, and Ansilex-93 ® when applicable, in a Cowles mixer. Sodium silicate (3.22 Si02/Na20) was then added into the slurry, along with sufficient water to form a mixture suitable for atomization. The slurry was spray dried in a pilot plant with a wheel-type atomizer. The weight percentages of each component of the slurry are set forth in Table 7. Again, the percentages of the alumina components are on a binder-free basis.
• the spray dried microspheres were calcined at 700°F for 4h and were used for the following crystallization.
• Example 10 Example 11 microsphere Example 8
• Example 9 grams microsphere 750 750 grams seeds 516 516 grams N-Brand 1367 1409 grams 50% caustic 124 147 grams water 638 687
• Examples 3, 6, and 7 These examples measure the performance of the catalysts of the present invention (Examples 3, 6, and 7) against that of two comparative examples.
• the two comparative examples represent the catalysts of U.S. Serial No. 09/956,250 (Comparative 1) and U.S. 5,395,908 (Comparative 2.
• the catalyst samples were laboratory deactivated at 1450°F for 4h in 100% steam.
• the deactivated catalysts were then tested in an ACETM fluidized bed test unit at 970°F with 1.125" injector height with an aromatic feed having a Conradson carbon of about 6%.
• the activity was changed by changing the amount of active FCC catalyst.
• the total amount of inert microspheres and active catalyst in the ACE unit was kept constant at 12.0 g.
• the yields are reported at 70% convention.
• Comparative catalysts 4 and 5 represent a class of catalysts for residuum cracking.
• the catalyst samples were presteamed at 1350°F for 2h in 100% steam, and 3000/3000 PPM Nickel and Vanadium were added via incipient wetness using nickel octoate and vanadium naphthenate, followed by poststeaming at 1450°F for 4h in a mixture of 90% steam and 10% air.
• the performance of each catalyst was then measured using ACE following the protocols described in the above Examples
• the catalysts of current invention show dramatic improvement in gasoline yield and bottom upgrading compared to comparative samples 3 and 4.
• the inventive catalysts also provide the lowest H2 yield among the catalysts tested, indicating better metal passivation.
• the catalyst of current invention results in a dramatic improvement in metal passivation as indicated by the low H2 yield.
• the catalyst of Example 10 contains no bottom cracking matrix such as spinel or mullite. Modification of this catalyst with the addition of small amounts of spinel and/or mullite would improve the bottom upgrading with little or no penalty in metal passivation.

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